Hosiery and dancewear with antimicrobial and moisture-wicking properties

ABSTRACT

A method for producing pantyhose and other nylon or spandex hosiery having long lasting antimicrobial and moisture-wicking properties. The method includes placing the pantyhose in a tub, adding a hydrophilic agent to the tub, adding an antimicrobial agent to the tub, adding dye mix and ammonia sulfate to the tub, heating contents of the tub until pores in the pantyhose expand to allow entry of hydrophilic agent molecules, antimicrobial agent molecules, and dye molecules, adding a color fixing agent to the tub, lowering a pH of the contents of the tub, and adding a softening mix to the tub.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of hosiery, including dancewear and intimate apparel, and relates more particularly to a method for producing hosiery having antimicrobial and moisture-wicking properties, wherein a desired color and handle of the hosiery is preserved and wherein such hosiery provides certain health benefits and greater comfort relative to traditional hosiery.

In today's fast-paced, progressive environment, comfort is often a dominant factor when consumers consider and select products for purchase. Such comfort-minded product selection is particularly evident in the hosiery industry, which provides clothing items that are typically worn in direct contact with the skin of an individual.

Due to the discomfort that is commonly associated with wearing traditional types of pantyhose, tights, and other hosiery items, the hosiery industry is currently in decline. While technological advancements have facilitated the development of hosiery made from softer yarns, such as microfiber, many women still find pantyhose and tights to be an uncomfortable burden, especially when worn for extended periods of time. Women often endure chaffing, scratching, tightness, sweating, irritability, and a general feeling of discomfort when wearing pantyhose and tights in exchange for maintaining a fashionable and/or professional appearance. Such discomfort is particularly prevalent among women who wear pantyhose and tights while performing physically demanding and/or high energy activities, such as waitressing, cocktailing, dancing, and sports, during which a wearer may perspire heavily.

In addition to being uncomfortable, traditional pantyhose and tights can trap bacteria and increase temperature in the genital area, and so can be the proximate cause or a contributing factor in the development of yeast infections (candidiasis) in wearers. The occurrence of bacterial vaginosis has also been linked to the wearing of pantyhose and tights, among other causes. Bacterial vaginosis can result in complications for pregnant women and has been associated with an increase in the development of pelvic inflammatory disease (PID) following surgical procedures such as a hysterectomy. The warm, moist environment created by nylon pantyhose and tights is also a predictive factor in the development of fungal infections of the skin of susceptible wearers, particularly in the feet, abdomen and genital areas. Preexisting fungal and allergic conditions, including eczema, athlete's foot, hives and rashes are exacerbated by the wearing of pantyhose and tights.

In view of the foregoing, it would be advantageous to provide a method for producing pantyhose and tights having long-lasting antimicrobial and moisture-wicking properties, wherein such pantyhose and tights are comfortable to wear and mitigate the risk of causing a wearer to develop or exacerbate bacterial and/or fungal infections. It would further be advantageous to provide such a method that preserves a desired color shade and handle of pantyhose and tights when antimicrobial and moisture-wicking finishes are applied thereto.

BRIEF SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a method for producing pantyhose and other nylon and spandex hosiery having long-lasting antimicrobial and moisture-wicking properties while preserving a desired color shade and handle of the hosiery. The method includes placing the pantyhose in a tub, adding a hydrophilic agent to the tub, adding an antimicrobial agent to the tub, adding dye mix and ammonia sulfate to the tub, heating contents of the tub until pores in the pantyhose expand to allow entry of hydrophilic agent molecules, antimicrobial agent molecules, and dye molecules, adding a color fixing agent to the tub, lowering a pH of the contents of the tub, and adding a softening mix to the tub.

The above-described method has been shown to produce pantyhose having antimicrobial and moisture-wicking properties having an average longevity of 15-20 washes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart illustrating a preferred embodiment of a method in accordance with the present disclosure.

In describing the preferred embodiment of the invention which is illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific term so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the flow chart shown in FIG. 1, an exemplary method for producing pantyhose having antimicrobial and moisture-wicking properties is provided. As used herein, the term “pantyhose” shall refer to any type of hosiery that is partially or entirely made from nylon or spandex, including, but not limited to, trouser socks, knee highs, thigh highs, leggings, tights, dancewear, body shapers, and traditional pantyhose, including footless varieties of each.

For the sake of convenience and clarity, only nylon pantyhose are mentioned in the following description of the inventive method. It should be understood, however, that the described method steps can be applied to any type of hosiery that is partially or entirely made from either nylon or spandex.

The method embodied by the present disclosure generally includes four steps: 1) pre-scouring; 2) antimicrobial and moisture-wicking finishing; 3) acid dying; and 4) softening. Each of these steps is described in detail below. Those of ordinary skill in the art will recognize that the described steps involve certain processes that are well known. It should be kept in mind, however, that it is the particular combination of these method steps, which include several processes that are believed to be novel in the context of the present disclosure, that has been found through extensive experimentation to be successful for the purpose of producing hosiery in a manner that imparts long-lasting antimicrobial and moisture-wicking properties and preserves the color and handle of the hosiery.

Pre-Scouring

Referring to the first step of the inventive method shown in FIG. 1, a quantity of undyed, unfinished pantyhose, commonly referred to as “greige goods,” is subjected to a pre-scouring process, whereby knitting oils are removed from the pantyhose. A non-limiting example of such a process may include placing the panty house in a tub filled with room-temperature water, heating the contents of the tub to about 90-110 degrees Fahrenheit, and circulating the contents of the tub for about 10 minutes. The water is then drained from the tub and the tub is refilled. A quantity of a scouring additive, such as about 0.9-1.1 grams/liter of an additive sold under the name MELASCOUR HOS-J, and a quantity of soda ash, such as about 1-2 grams/liter, are added to the tub. The contents of the tub are then heated to about 170-190 degrees Fahrenheit and are circulated for about 30 minutes. The contents of the tub are then cooled to about 130-150 degrees Fahrenheit and the tub is drained. The tub is then refilled with water and the contents of the tub are heated to about 130-150 degrees Fahrenheit and are circulated for about 10 minutes. The tub is then drained, refilled, and the contents of the tub are circulated for about 6 minutes. The tub is then drained and the scoured pantyhose are removed.

Antimicrobial and Moisture-Wicking Finishing

A second step in the process of the present disclosure involves imparting antimicrobial and moisture-wicking properties to the pantyhose. In a non-limiting example of this step, the pantyhose are added to a dye tube and the tub is filled with a quantity of water. A quantity of a hydrophilic agent, such as about 4-6% on-weight-goods (OWG) of a translucent emulsified copolymer (TEC) sold under the name MELAFINISH HPH, is added to the dye tub. The contents of the tube are then circulated for about 5 minutes. Next, a quantity of an acid leveling agent, such as about 1-3 grams/liter of a leveling agent sold under the name MELASSIST, is added to the dye tub. The contents of the tube are then circulated for about 5 minutes. Finally, a quantity of an antimicrobial (i.e., antibacterial and antifungal) agent, such as a triclosan-containing additive sold under the name MICROBAN, is added to the dye tub and the contents of the tub are circulated for about 5 minutes.

The introduction of the hydrophilic additive in the manner described above provides the pantyhose with extremely high fluid dynamic performance. Aqueous liquids, such as the sweat of a wearer, are rapidly and systematically wicked away through the fabric in all directions from the point of insult, thus resulting in a perceived “dry feel” to the wearer even while the fabric is still moist. This wicking also results in increased liquid surface, which leads to rapid drying and an associated cooling effect, which in-turn greatly enhances comfort to the wearer. This cooling and drying also creates a highly unfavorable environment for the growth and reproduction of microbes.

The introduction of the triclosan-containing additive in the manner described above provides the pantyhose with a microbe-resistant finish. Particularly, when a microbe comes into contact with the treated fibers of the pantyhose, the triclosan penetrates the cell wall of the microbe and disrupts the key functions of the cell so that the microbe cannot grow or reproduce. The growth and reproduction of bacteria and fungus in the pantyhose are thereby mitigated.

Acid Dying

Next, a dye mix and a quantity of ammonia sulfate are added to the dye tub. The dye mix is pre-formulated to produce a desired color shade in the pantyhose. The ammonia sulfate is introduced to lower the pH of the bath mix (i.e., the contents of the dye tube) at a very slow rate (slower than conventional acids) thereby slowing the strike rate of the dye mix. A slow strike rate promotes even distribution of the dye mix, which in-turn promotes even coloring and shading in the pantyhose. This is especially important for lighter dye mixes (e.g. those used to produce nude, near-nude, and flesh-tone pantyhose) which are more prone to produce visible spotting than darker dye mixes (e.g. those used to produce black or near-black pantyhose). For this reason, it is contemplated that conventional acids can be substituted for ammonia sulfate if darker dye mixes are used in the dying process.

The bath mix is circulated in the dye tub for approximately 10 minutes to allow thorough and even absorption of the dye mix and the previously-introduced TEC, leveling agent, and triclosan by the pantyhose. The bath mix is then heated to a preferred temperature of about 200-220 degrees Fahrenheit. Heating the bath mix in this manner causes the pores in the pantyhose fibers to open, thus allowing the molecules of the dye, TEC, leveling agent, and triclosan in the bath mix to enter the pores. After the heated bath mix is circulated for several minutes the pantyhose are cold rinsed.

Next, a color fix is added to the dye tub. The color fix is a resin composed of clear molecules that are smaller in size than the molecules of dye, TEC, leveling agent, and triclosan that have been deposited in the pores of the nylon. The color fix is introduced into the dye tub at a relatively cool water temperature and is circulated in the dye tub for at least five minutes to assure even distribution of the fix. An acid substitute, and preferably a diluted acid base containing Tanacid NA, is then added to the dye tub to lower the pH of the mix. The strike rate of the bath mix is thereby slowed, thus facilitating an even distribution of the color fix, dye, TEC, leveling agent, and triclosan. The introduction of the acid base into the bath mix also imparts a charge to the nylon pantyhose, thereby increasing the affinity of the oppositely-charged molecules of dye, resin, TEC, leveling agent, and triclosan for the nylon fibers.

Next, the bath mix is heated to a preferred temperature of about 150-170 degrees Fahrenheit, causing the pores in the nylon pantyhose to open. As the temperature in the bath mix rises, the pH level of the bath mix gradually decreases to a range of about 4.5-5.0, a level at which the acidic bath mix drives the molecules of the color fix, TEC, leveling agent, and triclosan into the pores of the nylon fibers. The color fix molecules fill into the empty spaces in the nylon pores that surround the larger molecules of dye, TEC, leveling agent, and triclosan, thereby firmly setting the large molecules within the pores. This can be likened to pouring sand into buckets full of large rocks, wherein the buckets are analogous to the nylon pores, the rocks are analogous to the dye, TEC, leveling agent, and triclosan molecules, and the grains of sand are analogous to the color fix molecules. The affinity of the charged dye, TEC, leveling agent, triclosan, and color fix molecules for the oppositely-charged nylon fibers causes the dye, TEC, leveling agent, triclosan, and color fix molecules to set even more firmly into the pores of the nylon, thus locking them into the pantyhose. This fixation process is critical for protecting the color shade of the pantyhose as well as for providing the pantyhose with long-lasting antimicrobial and moisture-wicking properties.

Softening/Finishing

Referring to the next step of the inventive method shown in FIG. 1, a softening mix is added to the dye tub. The softening mix preferably contains a standard 4% cationic nylon softener and a 1% diluted silicone softener. The softening mix is applied at a preferred temperature of about 100-120 degrees Fahrenheit, which is sufficient for causing the softening mix to adhere to the nylon pantyhose. The contents of the dye tub are then circulated to distribute the softening mix.

The application of the softening mix provides the pantyhose with a soft feel, or “handle.” The use of a diluted silicone softener is preferred for its longevity and exceptionally soft handle when applied to nylon. However, those of ordinary skill in the art will recognize that certain problems, including spotting and seam slippage, are associated with the use of silicone softening agents. Furthermore, silicone is much more expensive than other, traditional softeners. It is therefore contemplated that other suitable softening agents can be substituted for the described silicone softening agent without departing from the present invention.

After all of the steps of the above-described method have been completed, the finished pantyhose can be removed from the dye tub and passed along for further processing, such as tumble drying, boarding, and packaging. It has been found that the antimicrobial and moisture-wicking properties of the pantyhose can be maintained for a minimum of 10 and up to as many as 20 washes, which typically exceeds the useful life of a pair of pantyhose.

The inventive method thus provides a means for efficiently and effectively imparting long-lasting antimicrobial and moisture-wicking properties to various types of nylon spandex hosiery items while preserving the desired color shade of such items. The items produced by the inventive method exhibit superior feel, comfort, longevity, and antimicrobial properties relative to hosiery items that are produced using more traditional methods.

This detailed description in connection with the drawings is intended principally as a description of the presently preferred embodiments of the invention, and is not intended to represent the only form in which the present invention may be constructed or utilized. The description sets forth the designs, functions, means, and methods of implementing the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and features may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention and that various modifications may be adopted without departing from the invention or scope of the following claims. 

1. A method for producing pantyhose having long lasting antimicrobial and moisture-wicking properties, the method comprising: a) placing the pantyhose in a tub; b) adding a hydrophilic agent to the tub; c) adding an antimicrobial agent to the tub; d) adding dye mix and ammonia sulfate to the tub; e) heating contents of the tub until pores in the pantyhose expand to allow entry of hydrophilic agent molecules, antimicrobial agent molecules, and dye molecules; f) adding a color fixing agent to the tub; g) lowering a pH of the contents of the tub; and h) adding a softening mix to the tub.
 2. The method in accordance with claim 1, further comprising pre-scouring and rinsing the pantyhose to remove oil.
 3. The method in accordance with claim 1, further comprising adding an acid leveling agent to the tub after adding the hydrophilic agent to the tub.
 4. The method in accordance with claim 1, wherein lowering the pH of the contents of the tub comprises adding an acid substitute to the contents of the tub.
 5. The method in accordance with claim 4, wherein adding an acid substitute to the contents of the tub comprises adding a diluted acid base containing Tanacid NA to the contents of the tub.
 6. The method in accordance with claim 1, wherein lowering the pH of the contents of the tub comprises lowering the pH of the contents of the tub to a pH in a range between 4.5 and
 5. 7. The method in accordance with claim 1, wherein the step of adding a softening mix to the tub comprises adding a 4% cationic nylon softener and a 1% diluted silicone softener to the tub.
 8. The method in accordance with claim 1, wherein the step of adding a softening mix to the tub comprises adding a softening mix to the tub at a temperature in a range of 100 to 120 degrees Fahrenheit.
 9. The method in accordance with claim 1, wherein the step of heating the contents of the tub comprises heating the contents of the tub to a temperature in a range of 200-220 degrees Fahrenheit.
 10. The method in accordance with claim 1, further comprising heating the contents of the dye tub to a temperature in a range of 150-170 degrees Fahrenheit after the step of adding the color fixing agent to the contents of the tub.
 11. The method in accordance with claim 1, wherein the step of adding the hydrophilic agent to the tub comprises adding a quantity of 4%-6% OWG of translucent emulsified copolymer to the tub.
 12. The method in accordance with claim 1, wherein the step of adding the antimicrobial agent to the tub comprises adding a quantity of 1-3 grams/liter of triclosan to the tub.
 13. A method for producing pantyhose having long lasting antimicrobial and moisture-wicking properties, the method comprising: a) placing the pantyhose in a tub; b) prescouring and rinsing the pantyhose to remove oil; c) adding dye mix and ammonia sulfate to the tub; d) heating contents of the tub to a temperature in a range of 200-212 degrees Fahrenheit; e) cold rinsing the contents of the tub; f) adding a color fix to the contents of the tub; g) lowering a pH of the contents of the tub; h) heating the contents of the tub to a temperature in a range of 160-180 degrees Fahrenheit; i) adding a softening mix to the tub at a temperature in a range of 100-120 degrees Fahrenheit; and
 14. The method in accordance with claim 13, wherein lowering the pH of the contents of the tub comprises adding an acid substitute to the contents of the tub.
 15. The method in accordance with claim 14, wherein adding an acid substitute to the contents of the tub comprises adding a diluted acid base containing Tanacid NA to the contents of the tub.
 16. The method in accordance with claim 15, wherein lowering the pH of the contents of the tub comprises lowering the pH of the contents of the dye tub to a pH in a range between 4.5 and
 5. 17. The method in accordance with claim 13, further comprising adding an acid leveling agent to the tub after adding the hydrophilic agent to the tub.
 18. The method in accordance with claim 13, wherein the step of adding the hydrophilic agent to the tub comprises adding a quantity of 4%-6% OWG of translucent emulsified copolymer to the tub.
 19. The method in accordance with claim 13, wherein the step of adding the antimicrobial agent to the tub comprises adding a quantity of 1-3 grams/liter of triclosan to the tub. 